Below is a precise method statement that describes the steps for the installation of air conditioner equipment in a central AC system like exhaust fans, AHU, FCU and FAHU etc.
HVAC equipment installation involves working on height that requires strict health and safety measures, which are briefly explained in below section.
Modular Supervisors and foremen shall carry out regular and scheduled toolbox talks. Subjects for these talks are pre-determined and planned as per Tool Box Talk subjects.
Tool Box talks are conducted prior to the commencement of critical activities to reinforce policies and procedures specific to the activity, communicating ‘lessons learnt’ from hazards / incidents and reviewing Job Hazard Analysis.
Safety officer shall conduct toolbox talks for complex lifting and other activities which require extra precautions. Attendance at toolbox talks is closely monitored to ensure all employees receive regular and appropriate.
Risks, at each stage are evaluated, utilizing the matrices to determine the level of significance in terms of likelihood of occurrence and severity of hazard based on the allocated numerical values.
Below is list of specific tasks that require precautionary measures:
- Hot works
- Bolt Tensioning and Torqueing
- House Keeping (General)
- Pressure test using air.
- Equipment Installations
- Leak Testing
- Manual Handling
- Material handling using forklifts
- Pneumatic Testing
- Portable Electric Hand Tools
- Working at Heights, scaffoldings, ladders
- Working in Fabrication Areas (General)
A Certified First Aider shall be on site at all times whilst a First Aid Clinic shall be available for treatment of minor injuries.
In the event of an emergency, all workers shall assemble at an area which shall be allocated by a post sign and wait for further instructions.
This point shall be marked with a sign as “MUSTER POINT” or Assembly Point.
The Project Engineer and the HSE officers can assist employees and point them to the assembly point.
Employees shall be made familiar with the locations of “Muster Stations” through Safety Induction and regular Toll Box Meetings.
Personal Protective Equipment’s PPE’s
Following are the basic personal protective equipment (PPE) those are always used during construction activities to ensure safety of the personnel at construction site:
Protective Clothing: Protective clothing protects the body of the construction staff from hazardous substance.
Helmet: The most important part of the human body is the head. It needs utmost protection which is provided by a hard plastic helmet.
Safety Shoes: Maximum of the working space is occupied with machinery, construction materials which are made of hard metal and which make it clumsy for construction staff to walk around. Safety shoes ensure that nothing happens to the feet while working or walking at site.
Safety Hand gloves: Different types of hand gloves are provided. All these are used in operations wherein it becomes imperative to protect ones hands. Some of the gloves provided are heat resistant gloves to work on hot surface, cotton gloves for normal operation, welding gloves, chemical gloves etc.
Goggles: Eyes are the most sensitive part of the human body and in daily operations chances are very high for having an eye injury. Protective glass or goggles are used for eye protection, whereas welding goggles are used for welding operation which protects the eyes from high intensity spark.
Ear Muff/plug: Noisy construction environment is very high for human ears to bear. Even few minutes of exposure can lead to head ache, irritation and sometimes partial or full hearing loss. An ear muff or ear plug is used during construction activities which dampens the noise to a bearable decibel value.
Safety harness: To avoid a fall from heightened area, safety harness is used. Safety harness is donned by the operator at one end and tied at a strong point on the other end.
Face mask: Working on insulation surface, painting or cleaning involves minor hazardous particles which are harmful for human body if inhaled directly. To avoid this, face mask are provided which acts as shield from hazardous particle.
AC Equipment Pre Installation Requirements
Before any material to be installed, ensure that these have been inspected at site and have been approved at least by QC personnel and as required by the approved Inspection & Test Plan ITP.
Inspect all materials and verify that they are undamaged.
Makes sure that all materials specifications are Approved by Client
Ensure that, all installation procedures are in accordance with the Manufacturer Instructions and or in accordance with the project specifications.
Ensure type approval certificates are available as required and in accordance with the regulatory requirements and specifications.
Choose a dry storage site that is reasonably level and sturdy to prevent undue stress and damage.
Do not remove protective caps from duct and pipe connections until ready to connect ducting.
Cover entire ac unit with tarpaulin or heavy-duty plastic coverall. Secure cover with adequate tie downs.
Inspect the area where works to be carried to ensure that the area is in a condition to commence the equipment installation.
Follow approved drawings, project specifications and Manufacturer Instructions for the installation.
AC Equipment Installation FCU AHU FAHU
Only a qualified technician should be allowed to carry out installation works.
Where necessary, prepare detailed layout for unit installation and obtain customer/client approval.
Clean the area where the unit is to be installed.
Remove shipping spacers wherever applicable.
Install unit on the foundation/support, provide vibration dampers underneath the unit to suit the operating weight as required.
Provide adequate clearance for unit service access, provide sufficient clearance around the condenser coil for proper heat transfer.
Install all necessary wiring and necessary components in accordance with the manufacturer instructions and job requirements.
Now install a trapped condensate drain line at unit drain connection, with insulation and cladding as per scope and project specification.
Drain line to be tested as per proposed leak test / hydro test procedure.
Connect all ducts with the unit. Provide flexible connector between the unit and the ducts.
Tags to be provided for unit, pipes, Cables, ducts etc.
Ensure the equipment is tagged according to the project tagging philosophy
Suitable warning notice shall be installed on the packaged Air Conditioning unit for controlling unauthorized operation
Ensure that all the installations and hook up connections are as per the approved shop drawings and manufacturer recommendations.
Make sure that the installed Package units & accessories are free from damages
Ensure the maintenance accessibility.
Complete all the necessary inspection, functional tests and commissioning activities according to the mechanical completion inspection test and start-up / commissioning procedure.
Ventilation & Exhaust Fans Installation Method
Only qualified technician should be allowed to carry out the exhaust and ventilation fans installation.
Where necessary, prepare detailed layout for fans installation and obtain consultant/client approval.
Inspect the foundations/support for its correctness against approved drawings
Install exhaust fans as per AFC drawing providing the vibration pads underneath the unit to suit the operating weight as per manufacturer recommendation.
Provide adequate clearance for fans service access.
Install all necessary wiring and components in accordance with the manufacturer instructions and job requirements.
Tags with description to be provided for unit, cables, ducts etc.
Each fan shall be mechanically run tested at designed speed for a minimum period of 60 minutes.
The measured parameter shall be recorded.
Air performance data shall be documented.
As a minimum, flow rate, static pressure and fan speed shall be recorded for each fan.
Electrical load for all fans shall be recorded at full fan load.